Gage R&R Values

Gage R&R Part Number

Average & Range Method 1 2 3 4 5 6 7 8
Operator 1 Trial 1 161.4961 162.2592 157.2873 161.4750 163.5763
Enter your data here-> Trial2 161.6904 162.5676 157.9265 161.6504 163.5543
Trial3 161.6781 162.9255 157.1875 161.9317 163.5398
Trial4
Trial 5
Total 484.8646173 487.75238 472.4013 485.05704 490.670502
Average-Appraiser 1 161.6215391 162.58413 157.4671 161.68568 163.556834
Range1 0.194310878 0.6662879 0.738953 0.4567069 0.03649102
Operator 2 Trial 1 161.8816 162.5774 157.0895 161.7715 163.9537
Enter your data here-> Trial2 161.2112 162.3888 157.5727 161.8694 163.7125
Trial3 161.5222 162.4657 157.2784 161.0428 163.2659
Trial4
Trial 5
Total 484.6149751 487.43189 471.94061 484.68365 490.932086
Average-Appraiser 2 161.538325 162.4773 157.31354 161.56122 163.644029
Range2 0.670450781 0.1886307 0.4831995 0.8265998 0.68777652
Operator 3 Trial 1 161.8709 162.0450 157.3511 161.6893 163.6001
Enter your data here-> Trial2 161.3139 162.8474 157.2306 161.0780 163.3650
Trial3 161.0760 162.7531 157.4995 161.4139 163.2663
Trial4
Trial 5
Total 484.2607543 487.64553 472.08126 484.18124 490.231474
Average-Appraiser 3 161.4202514 162.54851 157.36042 161.39375 163.410491
Range3 0.794897398 0.802345 0.2689482 0.6112811 0.33380371

Range Average 0.5174 Constants

XDiff 0.1564 5 Trials 4 Trials 3 Trials 2 Trials # Trials 3
UCL 1.3348 2.11 2.28 2.58 3.27 D4 2.58
LCL 0.0000 0 0 0 0 D3 0
Repeatability(EV) 0.3057 0.577 0.729 1.023 1.88 A2 1.023
Reproducibility(AV) 0.0215 0.4299 0.4857 0.5908 0.8862 K1 0.5908
Gage Capability(R&R) 0.3064 0.7071 0.5231 K2 0.5231
Spec Tolerance 0.0100 2 Ops 3 Operators
Acceptability(%) 30.64

% Using % Using
AIAG - Automotive Industry Action Group Formul TV Tolerance
Equipment Variation (Repeatability) 0.3057
%EV 12.2% 18340%
Appraiser Variation (Reproducibility) 0.02150
%AV 0.9% 1290%
R&R (Gage Capability) 0.3064
%R&R 12.3% 18385%
PV (Part Variation) 2.4812
%PV 99.2% 148871%
TV (Total Variation) 2.5000

Conclusions / Recommendations
Gage system may be acceptable based on importance of application and cost
Gage may need maintenance, redesign, or better clamping

# Parts #Trials #Ops

5 3 3

Calculate GageR&R using Anova With Interaction Without Interaction

Anova Source df SS MS F P F P
Appraiser 2 ### ### -4 Err:502 -18.99994 Err:502
Parts 4 198.0884 49.522101 0.000381 1.00000 0.0018082 0.99999
Appraiser x Part 8 ### 130092.84 1452043 0.00000
Gage w AP Interaction 30 2.6878 0.0896
Gage w/o AP Interaction 38 ### ###
Total 44 201.104812

% Study
Estimate of Variance Std. Dev 5.15* Stdev Variation % Contribution
Repeatability 0.08959 0.299320814 EV 1.5415022 0% 0%
Appraiser 43364.2677922847 208.2408889 AV 1072.4406 65% 43%
AppraiserxPart 43364.2488819224 208.2408435 INT 1072.4403 65% 43%
R&R 86728.60627 294.4972093 R&R 1516.6606 93% 86%
Part 14449.25713 120.2050628 PV 619.05607 38% 14%
TV 1638.1361

Part by Appraiser Plot (Stacked)

166

164
Averagge

162

160

158

156

154
1 2 3 4 5 6 7 8 9
Part

Part by Appraiser Plot

166
 Part by Appraiser Plot

166

164
Averagge

162

160

158

156

154
1 2 3 4 5 1
Appraiser 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 Appr
Appraiser 2

Range of Parts by Appraiser (Stacked)

0.9

0.8

0.7
Range

0.6

0.5

0.4

0.3

0.2

0.1

0
1 2 3 4 5 6 7 8
Parts
 0.8

0.7

Range 0.6

0.5

0.4

0.3

0.2

0.1

0
1 2 3 4 5 6 7 8
Parts

Range of Parts by Appraiser

0.9

0.8

0.7
Range

0.6

0.5

0.4

0.3

0.2

0.1

0
1 2 3 4 5
Appraiser 61 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 Appr6
Appraiser 2
 0.7

Range
0.6

0.5

0.4

0.3

0.2

0.1

0
1 2 3 4 5
Appraiser 61 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 Appr6
Appraiser 2

Instructions 1. Select 10 DIFFERENT parts and at least two "appraisers" and one gage
(If you don't use enough parts, part variation will be small and magnify the appraiser/equipment variation)
2. RANDOMLY, have appraisers measure each part at least twice
3. Then enter the results of each measurement in Cells C3:L7, C11:L15, C19:L23
4. The template will automatically calculate all of the values based on your data
5. Evaluate your measurement system based on %R&R and make adjustments as required.

Gage Repeatability and Reproducibility

Measurement is one common cause of variation. Gage R&R helps improve measurement systems
If repeatability (EV - Can the same person using the same gauge measure the same thing consistently)
is larger than reproducibility, reasons include:
1. Gage instrument needs maintenance
2. Gage needs to be redesigned
3. Clamping or location needs to be improved
4. Excessive within-part variation

If reproducibility (AV-can two appraisers measure the same thing and get the same result)
is larger than repeatability, reasons include:
1. Operator needs to be better trained in how to use and read gage
2. Calibrations on gage are not clear
3. Fixture required to help operator use gage more consistently

Gage System Acceptability

%R&R<10% Gage System Okay (Most variation caused by parts, not people or equipment)
%R&R<30% May be acceptable based on importance of application and cost of gage or repair
%R&R>30% Gage system needs improvement (people and equipment cause over 1/3 of variation)

Verified using AIAG Measurement Systems Analysis 3rd Edition

Gage R&R Values Gage R&R Percentages

9 10 Sum
806.094
807.389
807.263
Xbar1 Reference
161.383056 12.500 <-Insert Reference Value Here
Bias
Rbar1 148.883
0.41854996
807.274
806.754
805.575
Xbar2 Reference
161.306881 12.500
Bias
Rbar2 148.807
0.57133147
806.557
805.835
806.009
Xbar3 Reference
161.226684 12.500
Bias
Rbar3 148.727
0.5622551

UCL represents the limit of the individual R's

Circle those beyond the limit.
Identify and correct causes
LCL = 0 D3=0 for up to 7 trials
ed)

Average-
Appraiser 1
Average-
Appraiser 2

7 8 9 10
 9 10 1 2 3 4 5 6
Appraiser 37 8 9 10

cked)

Rang
e1
Rang
e2

7 8 9 10
 Rang
e1
Rang
e2

7 8 9 10

9 10 1 2 3 4 5 6
Appraiser 37 8 9 10
 9 10 1 2 3 4 5 6
Appraiser 37 8 9 10

nce of application and cost of gage or repair

eople and equipment cause over 1/3 of variation)
 Range Method

Range Method Insert Your Data Here

Part 1 2 3 4 5 Average
Appraiser 1 12 22 12 10 11 13.4
Appraiser 2 11 23 13 12 21 16 d2
Range 1 1 1 2 10 3 1.19

GR&R 2.521008

Insert Process
Standard
Deviation 5.121849
%GR&R 49%

Page 12
 Bias

t-
Reference Average/ Stdev(r) Statistic/
Value Value Bias n Mean Stdev Stdev(b) critical
5.8 6.0 -0.2 15 6.006667 0.21202 0.2251409 0.114683
5.7 -0.3 Bias 0.0067 0.0581311 2.2064
5.9 -0.1
5.9 -0.1 95% Confidence
6.0 0.0 Lower Upper
6.1 0.1 -0.118656 0.131989
6.0 0.0 Bias Acceptable
6.1 0.1
6.4 0.4 Reference: AIAG MSA Version 3 pgs 85-88
6.3 0.3
6.0 0.0
6.1 0.1
6.2 0.2
5.6 -0.4
6.0 0.0

Page 13
 Bias

d2*/d2 df g 2 3 4 5 6 7
3.55333 10.8 d2* 1.41421 1.91155 2.23887 2.48124 2.67253 2.82981
3.47193 df 1 2 2.9 3.8 4.7 5.5
d2 1.12838 1.69257 2.05875 2.3593 2.53441 2.70436
t crit 95% 4.303 3.182 2.776 2.571 2.447 2.365

ersion 3 pgs 85-88

Page 14
 Bias

8 9 10 11 12 13 14 15 16
2.96288 3.07794 3.17905 3.26909 3.35016 3.42378 3.49116 3.55333 3.61071
6.3 7 7.7 8.3 9 9.6 10.2 10.8 11.3
2.8472 2.97003 3.07751 3.17287 3.25846 3.33598 3.40676 3.47193 3.53198
2.306 2.262 2.228 2.201 2.179 2.16 2.145 2.131 2.12

Page 15
 Bias

17 18 19 20
3.66422 3.71424 3.76118 3.80537
11.9 12.4 12.9 13.4
3.58788 3.64006 3.68896 3.735
2.11 2.101 2.093 2.086

Page 16
 Linearity

Part
Trials 1 2 3 4 5
1 2.7 <- Insert Your Data Here
2
3 Linearity evaluates a gauge
4 to measure accurately acro
5 Imagine measuring a baseb
6 1. at the grip
7 2. in the middle
8 3. and at the widest part
9
10
11
12
Average 2.70
Reference
Values 2.00 <- Insert Known Reference Values Her
Bias 0.70
Range 0.00 0.00 0.00 0.00 0.00
bias=
slope*ref+b
Slope= Err:502
b= Err:502
Goodness of fit Err:502
Insert Process
Variation
Linearity Err:502
%Linearity Err:502

Linearity Plot

0.80

0.70

0.60
Bias

0.50

0.40

0.30

0.20

0.10

0.00
1.50 2.00 2.50 3.00 3.50 4.00
Reference Value

Page 17
 Linearity

our Data Here

Linearity evaluates a gauge's ability

to measure accurately across a wide range
Imagine measuring a baseball bat:
1. at the grip
2. in the middle
3. and at the widest part

nown Reference Values Here

Page 18
 Appraiser A Appraiser B Appraiser C Reference Results
Part # Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3 Reference Ref Value Code LSL USL %R&R
1 1 1 1 1 1 1 1 1 1 1 0.476901 + 0.45 0.55 25%
2 0 0 0 0 0 0 0 0 0 0 0.576459 - 1. Enter Spec Limits Above
3 1 1 0 1 1 0 1 0 0 1 0.544951 X 2. Have 3 appraisers accept/reject 10+ par
4 0 - 3. Enter pass/fail in columns B-J
5 0 - 4. Enter Reference value in column L
6 0 - 5. Evaluate effectiveness columns AJ-AV
7 0 -
8 0 -
9 0 -
10 0 -
11 0 -
12 0 -
13 0 -
14 0 -
15 0 -
16 0 -
17 0 -
18 0 -
19 0 -
20 0 -
21 0 -
22 0 -
23 0 -
24 0 -
25 0 -
26 0 -
27 0 -
28 0 -
29 0 -
30 0 -
31 0 -
32 0 -
33 0 -
34 0 -
35 0 -
36 0 -
37 0 -
38 0 -
39 0 -
40 0 -
41 0 -
42 0 -
43 0 -
44 0 -
45 0 -
46 0 -
47 0 -
48 0 -
49 0 -
50 0 -
0 = Fail + = within spec limits
1 = Pass - = outside spec limits
x = gray area around spec limits
 A-B B-C C-A A-REF B-REF C-REF
Gray zone 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
0.02500 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
sers accept/reject 10+ parts 1 1 0 1 -1 0 1 -2 0 1 1 -2 1 1 -2 1 -2 -2 Crosstabulation Crosstabulation
in columns B-J B Total REF Total Effectiveness
ce value in column L A 0 1 A 0 1 A
tiveness columns AJ-AV 0 4 0 4 0 3 0 3 B
1 0 5 5 1 1 5 5 C
Total 4 5 9 Total 4 5 9 System

C Total REF Total Effectiveness

B 0 1 B 0 1 Acceptable
0 4 1 5 0 3 0 3 Marginal
1 0 4 4 1 1 5 6 Unacceptable
Total 4 5 9 Total 4 5 9

A Total REF Total

C 0 1 C 0 1
0 4 0 4 0 3 0 3
1 1 4 5 1 2 4 6
Total 5 4 9 Total 5 4 9
 Miss
Effectiveness Rate
89% 11%
89% 11%
78% 22%
85% 15%
85%
Effectiveness
Acceptable >= 90%
Marginal >=80%
Unacceptable <80%